Air Conditioner Condenser Booster

ABSTRACT

An architecture is presented that provides a an air conditioner booster device for improving the air flow across the condensing exchanger of an air conditioning unit thereby increasing the efficiency of the air conditioning unit. The air conditioner booster device is intended to increase the air flow created by a traditional air conditioner condenser fan. The air conditioner booster device is easily removably attachable to most conventional air conditioning units.

CROSS-REFERENCE

This application claims priority from Provisional Patent Application Ser. No. 61/448,425 filed Mar. 2, 2011.

FIELD OF THE INVENTION

This invention pertains generally to an air conditioner booster device for increasing the air flow across the condensing exchanger of an air conditioning unit.

BACKGROUND

Conventional whole-house or multi-compartment air conditioners typically utilize an outdoor condenser unit to allow for heat exchange from the higher temperature refrigerant gas to the relatively cooler external atmosphere. A condenser fan is used to increase airflow across the condensing exchanger of the condenser unit thereby speeding up the rate of heat exchange. The time that it takes for an air conditioning compressor, an evaporator fan, and the condenser fan to run through a complete cycle results in a large consumption of energy. The more kilowatt-hours used, the higher the users energy bills. This may result in a reluctance or inability to run an air conditioner unit to its full or desired capacity as there is a significant economic concern due to the cost of electricity.

Consequently, a more efficient air conditioner unit option that would lower energy consumption while maintaining a comfortable indoor temperature is needed. The proposed invention creates increased airflow across the condensing exchanger of air conditioning units, thereby effectively decreasing the length of time that the air conditioning compressor, condenser fan, and evaporator fan run in order to complete a cycle at the desired thermostat set point. It is adaptable to a wide variety of existing air conditioning products. Furthermore, the invention is designed to be used for the reduction of electrical energy typically consumed by residential or commercial air conditioning units by increasing the efficiency of the air conditioner.

SUMMARY

Accordingly, the present invention overcomes the limitations of the prior art by providing a unique and useful condenser booster device for an air conditioner that increases the efficiency of conventional residential and commercial air conditioning units.

The following presents a simplified summary in order to provide a basic understanding of some novel embodiments described herein. This summary is not an extensive overview, and it is not intended to identify key/critical elements or to delineate the scope thereof. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is presented later.

The subject matter disclosed and claimed herein, in one aspect thereof, comprises an condenser booster device for increasing airflow in an air conditioner condenser unit. The condenser booster device comprises a coupling element, a shaft extension element, and at least one supplemental fan element. The coupling element is selectively attachable to an existing fan motor shaft distal to the existing condenser fan. Additionally, the conditioner booster device is adjustable to fit a wide variety of existing air conditioner condenser units.

Furthermore, in the preferred embodiment of the invention, the shaft extension element attaches to the coupling element, thereby effectively extending the length of the existing fan motor shaft. One or more supplemental fans may be attached to the shaft extension element in a series arrangement. Once installed, the conditioner booster device increases the volume of air flow across a heat exchanging portion of the air conditioner condenser unit, thereby correspondingly increasing the rate of heat exchange.

To the accomplishment of the foregoing and related ends, certain illustrative aspects are described herein in connection with the following description and the annexed drawings. These aspects are indicative of the various ways in which the principles disclosed herein can be practiced and all aspects and equivalents thereof are intended to be within the scope of the claimed subject matter. Other advantages and novel features will become apparent from the following detailed description when considered in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a perspective view of a condenser element from a conventional air conditioner unit in accordance with the disclosed architecture.

FIG. 2 illustrates a perspective view of a condenser booster device attached to a condenser fan motor from the conventional air conditioner unit in accordance with the disclosed architecture.

FIG. 3 illustrates a perspective view of the condenser booster device attached to the condenser fan motor from the conventional air conditioner unit in accordance with the disclosed architecture.

DETAILED DESCRIPTION

The present invention discloses a condenser booster device for use with an air conditioner condenser unit. The preferred embodiment allows a user to increase the efficiency of existing air conditioning units by increasing the rate of heat exchange. A condenser booster device is selectively attachable to an existing fan motor shaft in the air conditioner condenser unit. Once the condenser booster device is attached, a fan motor controlling the existing fan motor shaft engages at least one supplemental fan element simultaneously with an existing condenser fan.

Reference is now made to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding thereof. It may be evident, however, that the novel embodiments can be practiced without these specific details. In other instances, well known structures and devices are shown in block diagram form in order to facilitate a description thereof. The intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the claimed subject matter.

Referring initially to the drawings, FIGS. 1 and 2 illustrate a prior art air conditioner 10 comprising an air conditioner condenser unit 20. The air conditioner condenser unit 20 typically comprises a condenser fan motor 30, a condenser motor shaft 40, and a condenser fan 50. Under normal usage, the condenser fan motor 30 drives the condenser motor shaft 40 which in turn causes the condenser fan 50 to rotate thereby moving a volume of air. The volume of air blows across and cools a compressed refrigerant within a condensing exchanger (not shown) which allows for heat exchange to occur. The greater the volume of air, the faster heat is exchanged. The invention therefore increases the efficiency of the air conditioner condenser unit 20 decreasing the run time and the cost of electricity.

Referring now to FIGS. 2 and 3, a condenser booster device 100 is illustrated for use with the air conditioner condenser unit 20. The condenser booster device 100 comprises a coupling element 102, a shaft extension element 104, and at least one supplemental fan element 110. The condenser booster device 100 is typically metal in composition, though it is contemplated that the condenser booster device 100 may comprise a variety of materials, such as but not limited to steel, aluminum, metal alloys, plastic, polymers, and the like without affecting the overall scope of the invention. For example, the coupling element 102 may be steel, the shaft extension element steel shafting, and the at least one supplemental fan element 110 plastic in one embodiment. Additionally, the size of the condenser booster device 100 is only limited by the size of the condenser unit 20. In other words, the condenser booster device 100 must fit inside the housing of the condenser unit 20.

The coupling element 102 is generally rigid and connects the shaft extension element 104 to the condenser fan motor shaft 40 at a point distal to the condenser fan 50. Preferably, the coupling element 102 is a metal sleeve type coupling dimensioned to encase both the condenser fan motor shaft 40 and the shaft extension element 104. For example, if the shaft extension element 104 is approximately ½ inches in diameter, the coupling element 104 would have an internal diameter of approximately ½ inches as well. Once in place around the condenser fan motor shaft 40 and the shaft extension element 104, the coupling element 102 may be removably secured in place with at least one attachment element, such as a set screw (not shown) for example. However, this is not meant as a limitation as any method of attaching and holding a coupling in place, such as but not limited by a screw, a spring, a clamp, a pin, a weld, and the like may be used without affecting the overall scope of the invention.

While the shaft extension element 104 is preferably steel shafting and approximately between two and twelve inches in length, this is not meant as a limitation as any length and diameter corresponding to the condenser motor shaft 40 may be employed. Similarly, the coupling element 102 would be appropriately sized to adapt to those dimensions. The shaft extension element 104 may comprise a material as discussed supra, as long as it is compatible with the coupling element 102.

A first end 106 of the shaft extension element 104 is coupled or otherwise connected to the condenser fan motor shaft 40 at a point distal to the condenser fan 50. The coupling element 102 allows the shaft extension element 104 to effectively increase the overall length of the condenser fan motor shaft 40. Additionally, the shaft extension element 104 may further comprise a plurality of sections (not shown) with a plurality of additional connecting elements (not shown). For example, the condenser booster device 100 could have an additional condenser device (not shown) connected in series to a second end 108 of the shaft extension element 104 with an additional coupling element (not shown).

As illustrated in FIG. 2, at least one supplemental fan element 110 is securably positionable along the length of the shaft extension element 104 at a position distal to the first end 106 of the shaft extension element 104. For example, the at least one supplemental fan element 110 may be located approximately at the second end 108 of the shaft extension element 104. Additionally, the at least one supplemental fan element 110 is typically metal, however any material such as plastic, as discussed supra, may be used.

FIG. 3 illustrates the condenser booster device 100 further comprising a plurality of supplemental fan elements 112 configured in a series arrangement removably securable along the length of the shaft extension element 104 distal to the first end 106 of the shaft extension element 104. Preferably, the plurality of supplemental fan elements 112 comprises a first supplemental fan element 114 and a second supplemental fan element 120 that may rotate at substantially the same speed. However, this is not meant as a limitation as the plurality of supplemental fan elements 112 may comprise any number that may fit within the dimensions of the condenser unit 20.

The plurality of supplemental fan elements 112 are typically smaller in diameter than the condenser fan 50 diameter from blade tip to blade tip, however, an embodiment where one of more of the plurality of supplemental fan elements 112 have the same diameter as the condenser fan 50 is considered to be within the scope of the invention. Similarly the plurality of supplemental fan elements 112 may have identical or different diameters. The plurality of supplemental fan elements 112 are typically between approximately eight and fifteen inches in diameter, however this is not meant as a limitation as applications may utilize diameters from four to thirty inches depending on the size of the condenser fan 50.

In the preferred embodiment, the first supplemental fan element 112 is securable to the shaft extension element 104 more proximally to the coupling element 102 than the second supplemental fan element 120. Additionally, the second supplemental fan element 120 is preferably smaller in diameter that the first supplemental fan element 114. In other words, the first supplemental fan element 114 is typically of a smaller diameter than the condenser fan 50, but of a larger diameter than the second supplemental fan element 120. However, as discussed supra, this is not meant as a limitation as the diameters of the first supplemental fan element 114 and the second supplemental fan element 120 may be approximately the same diameter as desired.

The at least one supplemental fan element 110 comprises a plurality of blades typically between two and twelve in number, although any number may be employed. In the preferred embodiment, the first supplemental fan element 114 comprises a plurality of first supplemental fan element fan blades 116, and the second supplemental fan element 120 comprises a plurality of second supplemental fan element fan blades 122. The plurality of first supplemental fan element fan blades 116 and the plurality of second supplemental fan element fan blades 122 typically have a pitch of approximately 32 degrees, although the pitch may range from 20 to 40 degrees and remain within the scope of the invention.

The first supplemental fan element 114 and the second supplemental fan element 120 are removably secured to the shaft extension element 104 with a first securing element 118 and a second securing element 124 respectively. The first and second securing elements 118 and 124 typically comprise at least one set screw, however any method of attachment known to one of skill in the art, including but not limited to screws, pins, bolts, welds, compression hardware, and the like may be used without affecting the overall scope of the invention. Additionally, the first supplemental fan element 114 and the second supplemental fan element 120 may be secured with plurality of first supplemental fan element fan blades 116 and the plurality of second supplemental fan element fan blades 122 either aligned or in a staggered arrangement.

What has been described above includes examples of the disclosed device. It is, of course, not possible to describe every conceivable combination of components and/or methodologies, but one of ordinary skill in the art may recognize that many further combinations and permutations are possible. Accordingly, the novel device is intended to embrace all such alterations, modifications and variations that fall within the spirit and scope of the appended claims. Furthermore, to the extent that the term “includes” is used in either the detailed description or the claims, such term is intended to be inclusive in a manner similar to the term “comprising” as “comprising” is interpreted when employed as a transitional word in a claim. 

1. A condenser booster device for coupling to a fan motor shaft in an air conditioner condenser unit, the condenser booster device comprising: a coupling element; a shaft extension element, wherein the coupling element connects the shaft extension element to the fan motor shaft; and at least one supplemental fan element, wherein the at least one supplemental fan element is positioned along the length of the shaft extension element.
 2. The condenser booster device of claim 1, wherein the condenser booster device is comprised of at least one of the following materials: steel, aluminum, metal, metal alloys, or plastic.
 3. The condenser booster device of claim 1, wherein the shaft extension element is between approximately two and twelve inches in length.
 4. The condenser booster device of claim 1, wherein the coupling element is removably secured to the fan motor shaft.
 5. The condenser booster device of claim 1, wherein the at least one supplemental fan element is plastic.
 6. The condenser booster device of claim 1, wherein the at least one supplemental fan element comprises a first supplemental fan element and a second supplemental fan element.
 7. A condenser booster device for coupling to an air conditioner condenser unit, wherein the air conditioner condenser unit comprises a fan motor, a fan shaft, and a condenser fan, the condenser booster device comprising: a rigid coupling element securable to the fan motor shaft; a shaft extension element, wherein the a first end of the shaft extension element is securable to the rigid coupling element; and at least one supplemental fan element, wherein the at least one supplemental fan element is of a smaller diameter than the condenser fan and is securable along the length of the shaft extension element distal to the first end of the shaft extension element.
 8. The condenser booster device of claim 7, wherein the at least one supplemental fan element comprises a plurality of blades numbering between 2 and
 12. 9. The condenser booster device of claim 7, wherein the at least one supplemental fan element comprises a first supplemental fan element and a second supplemental fan element.
 10. The condenser booster device of claim 9, wherein the first supplemental fan element is positioned along the shaft extension element more proximal to the rigid coupling element than the second supplemental fan element.
 11. The condenser booster device of claim 10, wherein the second supplemental fan element is smaller in diameter than the first supplemental fan element.
 12. The condenser booster device of claim 7, wherein the first supplemental fan element and the second supplemental fan element rotate at substantially the same rate.
 13. The condenser booster device of claim 7, wherein the first supplemental fan element and the second supplemental fan element are removably secured to the shaft extension element.
 14. The condenser booster device of claim 7, wherein the first supplemental fan element and the second supplemental fan element are of substantially the same diameter.
 15. A condenser booster device for coupling to an air conditioner condenser unit, wherein the air conditioner condenser unit comprises a fan motor, a fan shaft, and a condenser fan, the condenser booster device comprising: a rigid coupling element securable to the fan motor shaft; a shaft extension element, wherein the a first end of the shaft extension element is securable to the rigid coupling element; and a plurality of supplemental fan elements, wherein the plurality of supplemental fan elements are smaller in diameter than the condenser fan and are securable along the length of the shaft extension element distal to the first end of the shaft extension element, and wherein the plurality of supplemental fan elements are of different diameters.
 16. The condenser booster device of claim 15, wherein the plurality of supplemental fan elements each comprise a plurality of blades pitched at between approximately 20 and 40 degrees.
 17. The condenser booster device of claim 16, wherein the plurality of blades are pitched at approximately 32 degrees.
 18. The condenser booster device of claim 15, wherein the plurality of supplemental fan elements are between approximately eight and fifteen inches in diameter.
 19. The condenser booster device of claim 15, wherein the shaft extension element comprises a plurality of sections.
 20. The condenser booster device of claim 15, wherein the plurality of supplemental fan elements each comprise a plurality of blades positioned in a staggered arrangement. 